Apparatus and method for demetallizing a metallized film

Abstract

A system and method for at least partially demetallizing a metallized film that has a metallized side and an opposite support side. In one embodiment, the method includes rotating a heat transfer roller about an axis such that a surface of the heat transfer roller passes a heating region, a printing region and a contacting region in sequence during each rotation; heating the heat transfer roller to a first temperature; applying the film to a portion of the surface of the heated heat transfer roller with the metallized side of the film facing away from the surface of the heat transfer roller; transferring heat from the heated heat transfer roller to the film in the heating region; printing an etchant solution at a second temperature, which is lower than the first temperature, in a predetermined pattern on the metallized side of the film in the printing region, and subsequently transferring heat from the heated heat transfer roller to the film to demetallize the metallized side of the film according to the predetermined pattern in the contacting region.

1. A method of at least partially demetallizing a film, wherein the film has a metallized side and an opposite support side, comprising:
 positioning the film on at least a portion of a moving surface with the metallized side of the film facing away from the surface so that the film is carried by the moving surface, the moving surface being at a first temperature; 
 transferring heat from the moving surface to the film to heat the film to substantially the first temperature; 
 printing an etchant solution in a pre-determined pattern on the metallized side of the film, the etchant solution being at a second temperature that is lower than the first temperature; 
 etching the metallized side of the film in said pattern; and 
 laminating the film to a backing material with the metallized side of the film facing the backing material. 
 
   
   
     2. The method of  claim 1 , wherein the moving surface is maintained at the first temperature. 
   
   
     3. The method of  claim 2 , wherein the positioning step comprises wrapping the film at least partially about at least a portion of a roller that is rotatable about an axis, the roller having an exterior surface that forms the moving surface. 
   
   
     4. The method of  claim 1 , wherein the backing material has a first side having a lamination, and wherein the laminating step comprises engaging the metallized side of the film to the first side of the backing material. 
   
   
     5. The method of  claim 4 , wherein the engaging step comprises heating the film and the backing material together to a third temperature and then cooling the film and the backing material to a fourth temperature, wherein the fourth temperature is lower than the third temperature. 
   
   
     6. The method of  claim 5 , wherein the heating step comprises engaging the film and the backing material on a second heat transfer roller heated to the third temperature. 
   
   
     7. The method of  claim 5 , wherein the cooling step comprises of engaging the film and the backing material on a third heat transfer roller heated to the fourth temperature. 
   
   
     8. A method of at least partially demetallizing a metallized film, wherein the film has a metallized side and an opposite support side, comprising:
 rotating a heat transfer roller about an axis, the heat transfer roller having an exterior surface, the exterior surface of the heat transfer roller sequentially passing a heating region, a printing region and a contacting region during each rotation; 
 heating the heat transfer roller to a first temperature; 
 positioning the support side of the film on and about at least a portion of the exterior surface of the heated heat transfer roller so that the metallized side of the film faces away therefrom; 
 transferring heat from the heat transfer roller to the film through the support side of the film in the heating region to heat the film to substantially the first temperature; 
 printing an etchant solution at a second temperature in a predetermined pattern on the metallized side of the film in the printing region; and 
 transferring heat from the heated heat transfer roller, along the contacting region, to the film and the etchant solution to demetallize the pattern in the metallized side of the film. 
 
   
   
     9. The method of  claim 8 , wherein the second temperature is lower than the first temperature. 
   
   
     10. The method of  claim 8 , wherein the printing step further comprises providing a print transfer roller with the etchant solution pattern thereon and transferring the etchant solution pattern from the print transfer roller to the metallized side of the film when the film passes between a portion of the print transfer roller and the heat transfer roller. 
   
   
     11. The method of  claim 10 , further comprising providing the etchant solution to the print transfer roller. 
   
   
     12. The method of  claim 11 , wherein the etchant solution is provided from a supply of the etchant solution. 
   
   
     13. The method of  claim 12 , wherein the etchant solution has a pH value in the range of from 10 to 14 pH. 
   
   
     14. A method of at least partially demetallizing a metallized film, wherein the film has a metallized side and an opposite support side, comprising: providing a moving surface;
 heating the moving surface to a first temperature; 
 positioning the film on a portion of the moving surface with the support side of the film in contact with the portion of the moving surface so that the film is heated to substantially the first temperature; and 
 printing an etchant solution at a second temperature in a predetermined pattern on the metallized side of the film in the printing region. 
 
   
   
     15. The method of  claim 14 , further comprising maintaining the film with the etchant solution pattern in contact with the portion of the moving surface for a predetermined time period so that, when in contact, heat is continuously transferred from the moving surface to the film to facilitate the demetallization of the metallized side of the film. 
   
   
     16. The method of  claim 15 , wherein the providing step comprises rotating a heat transfer roller about an axis, the heat transfer roller having an exterior surface that forms the moving surface. 
   
   
     17. The method of  claim 15 , wherein the providing step comprises moving at least a part of a heat transfer assembly, a portion of the heat transfer assembly forming the moving surface. 
   
   
     18. The method of  claim 14 , wherein the second temperature is lower than the first temperature. 
   
   
     19. The method of  claim 18 , wherein the printing step further comprises providing a print transfer roller with the etchant solution pattern thereon in spaced operative cooperation with a portion of the moving surface and transferring the etchant solution pattern from the print transfer roller to the metallized side of the film when the film passes between the print transfer roller and the portion of the moving surface. 
   
   
     20. A method of at least partially demetallizing a metallized film, wherein the film has a metallized side and an opposite support side, comprising:
 heating the film substantially to a first temperature; and 
 printing an etchant solution at a second temperature in a predetermined pattern on the metallized side of the heated film, 
 wherein the second temperature is lower than the first temperature. 
 
   
   
     21. The method of  claim 20 , wherein the heating step comprises: providing a moving surface;
 heating the moving surface to the first temperature; and 
 positioning the film on a portion of the moving surface with the support side of the film in contact with the portion of the moving surface so that the film is heated to the first temperature. 
 
   
   
     22. The method of  claim 21 , wherein the providing step comprises rotating a heat transfer roller about an axis, the heat transfer roller having an exterior surface that forms the moving surface. 
   
   
     23. The method of  claim 21 , wherein the providing step comprises moving at least part of a heat transfer assembly, a portion of the heat transfer assembly forming the moving surface. 
   
   
     24. The method of  claim 21 , wherein the printing step further comprises:
 providing a print transfer roller positioned in spaced operative cooperation with a portion of the moving surface, the print transfer roller having the etchant solution pattern thereon; and 
 transferring the etchant solution pattern from the print transfer roller to the metallized side of the film when the film passes between the print transfer roller and the portion of the moving surface. 
 
   
   
     25. The method of  claim 24 , further comprising keeping the film substantially at the first temperature for a predetermined time period to accelerate the demetallization of the pattern on the metallized side of the film. 
   
   
     26. The method of  claim 20 , further comprising:
 preparing a backing material having a first side and a second side, the first side having a lamination; 
 applying the film to the backing material with the metallized side of the film facing the first side of the backing material; and 
 laminating the film to the backing material. 
 
   
   
     27. The method of  claim 26 , wherein the laminating step comprises:
 heating the film and the backing material together to a third temperature; and cooling the film and the backing material together to a fourth temperature, 
 wherein the fourth temperature is lower than the third temperature. 
 
   
   
     28. The method of  claim 27 , wherein the heating step comprises engaging the film and the backing material together with a second heat transfer roller heated at the third temperature. 
   
   
     29. The method of  claim 27 , wherein the cooling step comprises engaging the film and the backing material together with a third heat transfer roller kept at the fourth temperature.